Textile Industry Experts Exchange Cutting-Edge Technologies For Energy Conservation And Emission Reduction

　　 Promote energy saving space in eight fields

Zhengzhou Hongda New Spinning Technology Consulting Co., Ltd. Wang Weimin

Core view: the entire textile industry is facing environmental pressure, the government is facing indicator pressure, and enterprises are facing capital, technology, and cost pressure. If the development of printing and dyeing industry is restricted by environmental protection, it will affect the entire textile industry, and the pressure of emission reduction is far greater than energy conservation. Therefore, enterprises must pay attention to the ecological problems in each link of the production process and accelerate the promotion of energy conservation and emission reduction.

Since 2011, the Environment and Assets Supervision and Administration Commission of China Textile Union has organized experts to carry out "free diagnosis" for energy conservation for 8 enterprises, including Jiangsu Dasheng Group Co., Ltd., Wuxi First Cotton Textile Factory, Anhui Huamao Group Co., Ltd., China Resources Textile Group Co., Ltd., Mutai Textile Holdings Co., Ltd., Joyful Home Textile, Jiangsu Sunshine Group, Yaguang Home Textile, and give relevant suggestions for technical transformation. Through free clinic, we believe that enterprises should transform from labor-intensive to technology intensive, like Wuxi Yimian, with high quality, low energy consumption, less labor, and 25 workers for 10000 ingots; It should gather in the park from a decentralized way, with high resource allocation and low cost; We should expand from low level to industrial chain integration, make high-end products and extend the industrial chain; It is necessary to change from high energy consumption to low-carbon ecology, because it can directly reduce costs.

In terms of building system energy conservation, it is recommended to revise the energy conservation design code for cotton textile plant, balance the utilization of waste heat (hot air) in process plant, reserve photoelectric and photothermal loads in roof design, reserve rainwater collection and reuse system in water supply and drainage design, and consider the design of multi-storey plant.

In terms of energy saving of air conditioning system, it is recommended to standardize the air conditioning design standards of cotton textile workshops and establish regional design specifications; Standardize the technical equipment catalog of textile air conditioning fan, spray, refrigeration and heating; The air conditioner shall adopt efficient motor and functional control, strengthen the balance utilization of waste heat (hot air) in winter, and adopt various cooling methods in summer.

In terms of energy saving of motor system, it is recommended to equip motors reasonably according to load, and YE3 (Class II) YE2、YX3， Reasonably select variable frequency motor and conduct economic analysis for replacement of motor.

In terms of energy conservation of boiler system, clean fuels such as natural gas, biomass fuel, condensate reuse, and efficient insulation measures of pipeline can be used to reduce heat loss.

In terms of clean power quality, for the single machine with large current and power, it can use the nearest governance to filter harmonics; For single machine equipment with small current and power, multi machine remote management can be adopted; It is suggested to use active filter device and increase series reactor to reduce harmonic amplification by capacitor; Build an online power quality monitoring system in order to discover the hidden harm of harmonics to the system in time.

For air compressor system, it is recommended to install air compressor cluster expert control system, air compressor energy-saving auxiliary system, desiccant, water pump, gas storage tank, cooling circulating water monitoring system, power metering, gas flow metering management system, and gas supply pipeline detection system; The compressed air pressure, air tank capacity, pipe diameter and process flow shall be reasonably selected according to the process requirements; Reasonably select the location of the air compression station and effectively use the air compression hot air and hot water recovery, configure the number of centrifuges and screw machines to meet the best matching of energy consumption, and configure the power frequency machine and frequency converter to adapt to the gas volume fluctuation.

In terms of energy management system, the enterprise energy consumption online monitoring and management platform can better solve the problems such as manual meter reading reports, serious lag in data analysis, strong randomness of data, and failure to feed back in time. Building an energy online monitoring and management system and production network management and control system can reduce the operating cost of the energy system, improve labor productivity, and improve the response speed to emergencies, Optimize power dispatching and balance power consumption to save power consumption.

In terms of process management system, the drafting and distribution process shall be designed reasonably; On the premise of satisfying the quality, the cotton should be properly mixed to improve the production rate and reduce the unit consumption; Ensure the equipment status, reasonably select and match the equipment, improve the unit output of equipment and reduce energy consumption; Reasonably allocate the air conditioning system to meet the optimal temperature and humidity of spinning and weaving processes; The weaving system reasonably allocates yarn quality and sizing quality.

　　 Five key points to achieve cleaner production

Guangzhou Hongyu Environmental Protection Technology Co., Ltd. Yang Aimin

Core point: Clean production is a new thing, a way of thinking and a method. We need to correctly understand and apply the principles and methods of cleaner production, fully mobilize the leaders and employees of the enterprise, improve management, change thinking, constantly find space for energy conservation and consumption reduction, find places that can reduce production costs, and find ways to reduce pollution generation and emissions. Clean production is a continuous work, a continuous process, which needs long-term persistence of enterprises.

After years of cleaner production practice, we summarize the following five key points:

First, attach importance to source control. Material and energy consumption, pollutant emissions, accidents and problems are the three sources of cleaner production for textile printing and dyeing enterprises. To be specific, controlling the source of material and energy consumption is to control costs, which most enterprises attach great importance to; Controlling the source of pollutants is to reduce unnecessary pollution; The source of controlling accidents and problems is to control costs, which requires a series of systematic work to achieve the goal, such as controlling the success rate of the process.

The second is to systematically save energy and water. After years of publicity and guidance, most enterprises have attached importance to the work and technology of energy conservation and water conservation. However, without specific or systematic analysis of water conservation and energy conservation in specific practice, the efficiency will be greatly reduced and some unnecessary losses may occur. The correct approach should make a systematic analysis of water consumption and energy consumption, and determine the implementation plan and measures based on the systematic analysis. For example, in the process of fabric washing, enterprises can reduce energy consumption by lowering the water temperature. However, if the waste heat recovery work is well done and there is more high-temperature hot water, then the method of increasing the washing temperature and reducing the number of washing times can be used to save water.

Third, boldly use new technologies and equipment. At present, the enthusiasm of enterprises to use new equipment and new technology has greatly improved, but there are still some enterprises limited to inertial thinking in the process of using new equipment and new technology. For example, in batch dyeing, people are willing to accept low bath ratio dyeing technology such as air flow dyeing machine, but less willing to accept cold stack dyeing technology. This is not only restricted by the lack of technical personnel, but also related to the consciousness of the person in charge.

Fourth, improve management means and strengthen management ability. It is necessary to invest funds to purchase equipment, implement water-saving and energy-saving and cleaner production projects, which can greatly improve the cleaner production level of enterprises. However, it is unrealistic to place all the hopes of improving the cleaner production level of enterprises on the investment of equipment, which should also be realized through management. On the contrary, under the existing conditions, the level of cleaner production can be improved by strengthening management. With the continuous development of various technologies, the management means should also be improved, and should not stay in the past. Therefore, in terms of management, we should not only strengthen, but also have institutional innovation to adapt to the development of the new situation.

Fifth, we should strive to overcome some problems in the printing and dyeing industry. Such as attaching importance to details and systems, equipment and management, investment and maintenance, hardware and talents.

　 The development prospect of solar thermal utilization technology is broad

Miao Jingyi of Beijing Zhongke Xiyuan Energy Saving Technology Co., Ltd

Core view: according to the energy demand of China's industrial field and the requirements of low-cost and large-scale utilization of solar energy, develop a feasible and efficient unit solar energy intermediate temperature conversion and utilization device, promote the industrialization and large-scale utilization of solar energy intermediate temperature heat collection device, and improve the efficiency and reliability of the intermediate temperature solar energy gathering and conversion device, It is of great significance to promote the application of solar energy in many fields such as industrial heating.

Due to the poor communication of information and technology between solar thermal utilization and main industrial energy use industries, the application of solar thermal utilization technology in China's industrial field is relatively slow. Except Changshu Kaida Printing and Dyeing Factory, Foshan Jialida Textile Printing and Dyeing Factory and Zhejiang Dali Printing and Dyeing Factory, several companies use solar thermal utilization technology, It is rarely used by other enterprises. The research on the application of solar thermal utilization technology in the industrial field abroad began in the late 1970s. 12 countries in Europe and the United States have investigated and studied the grade of heat consumption in the industrial field. The International Energy Agency launched the Solar Energy Heating and Cooling Program (IEASHC) in 1976 and the Solar Thermal Power and Solar Chemical Energy System Program (SolarPACE Program) with the United States, Russia, Germany, Australia, Israel, Switzerland and Spain as the executive committee in 1977.

The industrial sector is the largest consumer of energy in China. According to statistics, the total energy consumed by industrial production accounts for about 70% of the total energy consumption in the country, of which 50%~70% is the heat used for industrial processing. For different industrial sectors, the distribution of heat load is also different, but the temperature generally does not exceed 250 ℃, and the pressure is below 9 atmospheres. According to the heat demand of industrial thermal process, nine industries including tobacco, textile, medicine, food, paper making and building materials are selected to analyze the heating potential of solar energy industry. The GDP of these industries accounts for 22.5% of the total industrial output, and the energy consumption of the industries studied accounts for more than 22.7% of the total industrial energy consumption.

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In China, the thermal energy consumption of the above industries varies greatly due to their different production processes. According to the data in 2007, chemical industry, paper industry, food processing industry and textile industry have relatively high energy consumption value of heating power. In the future development, paper industry, food industry and textile industry have great potential to apply solar thermal technology. It is estimated that if 10% of the heating energy used in various industries is provided by solar energy, the required collector area will reach 1.1 billion square meters. The industry studied has 10% thermal energy substitution, with an annual energy saving of 26.63 million tons and carbon dioxide emission reduction of 93.34 million tons. The required collector area is 273.33 million square meters, which is far larger than the installation area of existing solar water heater system collectors. According to the current installed amount of solar hot water system heat collection area of 150 million square meters, and the annual output value of 65 billion yuan, solar industrial heating is popularized and applied in the analyzed industry. 10% of the thermal energy consumption is replaced by solar medium temperature heating, and the annual output value can reach at least 100 billion yuan. The corresponding annual coal saving is about 100 million tons, and the simple calculation corresponds to the emission reduction of 320 million tons of carbon dioxide, According to China's emissions of 6.2 billion tons of carbon dioxide in 2006, the emission reduction can be about 5%.

　　 Realized at three levels Digitization of printing and dyeing

Changzhou Hongda Technology Group Gu Ren

Core point: The successful application of the intelligent information management and control system for textile printing and dyeing has greatly improved the automation of the production process of textile printing and dyeing enterprises. Through the realization of digital management of the production process, it provides a strong support for enterprise upgrading, ensures the optimization of the production process, improves product quality, improves workers' production conditions, and fundamentally changes the production mode of enterprises, Thus, the production and management costs are greatly reduced, the consumption of raw materials is saved, and the pollution discharge is reduced.

According to the actual situation of the existing equipment and printing and dyeing enterprises in China, Changzhou Hongda realizes the digital control of printing and dyeing and improves the automation and intelligent informatization level of the printing and dyeing industry through the promotion and application of the following three levels.

The first is to realize online detection and automatic control of the key process parameters of the existing production process: it is mainly to realize the automatic control of a single key point or several key process parameters of a certain processing technology. It includes online measurement and control of process parameters such as concentrated alkali concentration, pH value, moisture content, air separation humidity, fabric width, fabric seam head, hydrogen peroxide concentration, etc.

The second is to realize the automatic control and digital management of a single machine: through the quantitative control of the process parameters of a single machine, the error caused by human factors is overcome, and the reproducibility is well realized by memorizing and storing the process menu, which greatly improves the one-time success rate. The main products include: intelligent digital information integration solutions for desizing, boiling and bleaching machines, intelligent digital information integration solutions for dyeing machines, intelligent digital information integration solutions for mercerizing machines, etc.

Third, realize the digital control and digital management of the production process: mainly the continuous detection control and network digital management of various processes in the printing and dyeing production process, effectively manage the water, electricity, gas energy consumption, output and yield in the production process, and achieve the purpose of digital control of printing and dyeing.

The company's printing and dyeing intelligent information control system products have been successfully applied in printing and dyeing enterprises in Zhejiang, Shandong, Fujian, Guangdong, Jiangsu and other provinces, such as Zhejiang Huili, Zhejiang Qingmao, Zhejiang Qingfeng, Zhejiang Xinyue Dyeing and Finishing, Hangzhou Tiancheng Printing and Dyeing, Guangdong Yida Printing and Dyeing, Jiangsu Lianfa Co., Ltd., Shandong Ruyi Group, Shandong Youyue Home Textile, Qingdao Phoenix Dongxiang Printing and Dyeing Shandong Lutai Textile Co., Ltd., Xiamen Hualun, New Xiefeng (Fujian) Printing and Dyeing, Guangdong Qianjin Denim, Guangdong Foshan Nanfang Printing and Dyeing Co., Ltd., Nanhai Yongqixiang Weaving and Dyeing, Yixing Leqi, etc. have been well received by users.

After launching a series of automatic, intelligent and information-based online testing products to help printing and dyeing enterprises achieve energy saving and emission reduction, the company has also successfully developed a series of automated products such as digital test cloth system, energy-saving intelligent control system for textile air conditioning, intelligent online monitoring system for ring spinning, etc, Provide support for textile enterprises to achieve energy conservation and emission reduction.

The digital test cloth system uses machine vision technology instead of human eyes to detect cloth defects in motion. At present, there is no precedent in China. The repeatability, objectivity and long-term stability of machine vision application are better than those of human eyes. Applying machine vision to fabric defect detection can not only reduce the loss caused by quality problems of ex factory products, but also greatly reduce the number of detection workers. Therefore, it can greatly improve the annual net profit of enterprises.

"Energy saving intelligent control system of textile air conditioning" can automatically adjust the air in the workshop to the optimal state by controlling, adjusting and monitoring all air processing processes; The expert module of D-Ctrl 6000 System is used to calculate the optimal operation data in coordination with special sensors, transmitters and optimal control algorithms on site. Through the on-site execution system, the opening of fan motor, water pump motor, water pump valve and the proportion of new return air are timely adjusted, and the appropriate outdoor air is fully used to obtain free air conditioning, which can realize independent control according to weather conditions and production process changes, meet the high-precision temperature and humidity requirements of the production workshop, and improve the quality of fabrics, Enhance the level of enterprise management, reduce the running time and energy consumption of refrigerators and fans, reduce equipment maintenance costs, extend equipment life, and reduce production costs. On the basis of existing textile air conditioners equipped with frequency converters, energy saving and consumption reduction can reach about 30%.

　　“ Ring spinning intelligence The online monitoring system is composed of single point monitoring indication, ingot group indication, machine terminal display and central database terminal comprehensive analysis to realize online monitoring and indication of yarn breakage and spindle belt slip in the production process of ring spinning machines. The machine terminal transmits the yarn breakage and spindle belt slip data to the central database terminal through the field bus in real time for unified analysis of the data, Through some rule bases, the possible problem yarn spindles are judged and predicted to provide a basis for user maintenance.

Changzhou Hongda will further increase its research and development investment in the automatic weighing and distribution system of dye powder, production process logistics management system and other aspects, improve the product system, gradually form the industry standard of products, establish the protection system of intellectual property rights, and lead China's printing and dyeing industry into a new digital era.

　　 Pugong tea saponin—— Small auxiliaries General use of

Shanghai Jintang Textile New Material Technology Co., Ltd. Zhang Zhijun

Core point: The application of Pugong tea saponin can not only produce good economic benefits, but also bring good social and environmental benefits. Due to the decrease of energy consumption and water consumption, the contradiction of energy shortage can be better alleviated. Due to the decrease of emissions and wastewater pollution indicators, and the improvement of sewage biodegradability, sewage is easier to treat. Compared with the original conventional process, it is conducive to environmental protection.

In June 2009, a product, Bugong tea saponin, which can replace alkali agent, auxiliary auxiliary agent and hydrogen peroxide for fabric pretreatment, was successfully developed. This product can be used in the pretreatment process of pure cotton, chemical fiber, blending, linen, flocking, batik and other fabrics, which can reduce the use of chemicals and alleviate the problem of excessive wastewater and heavy pollution in the pretreatment stage of printing and dyeing plants. In the next four months, the product was approved and applied in Shanghai Tiqiao, Shanghai Jingsheng, Zhejiang Zhongfang Group, Ibena (Germany) and other dyeing plants. As of October 2013, the sales volume of Pugong tea saponin reached 873.86 tons, double that of the same period in 2012. At present, more than 50 domestic enterprises, 5 printing and dyeing plants in Indonesia, India, Singapore, Bangladesh and other countries are using Pugong tea saponin products. In 2013, the company added 25 new customers. The use of Pugong tea saponin has enabled these printing and dyeing plants to achieve cost reduction, efficiency increase, energy conservation and emission reduction.

Through the feedback information from the dyeing factory after using Pugong tea saponin products, we know that:

Bugong tea saponin used on pure cotton woven fabric can reduce the use of steam by 20%, shorten the process flow by 1/3, and avoid the use of 1 steam box and 5 water washing tanks. The fabric has little strength damage and will not appear oxidation holes. Especially for those low-quality batik fabrics, the use of Bugong tea saponin pretreatment can improve the strength of the fabric, and avoid the risk of oxidative damage. The gross effect, whiteness and other indicators meet the printing requirements of wax dyed fabrics. At the same time, greatly reducing the amount of chemicals is conducive to wastewater treatment and reducing wastewater discharge, and it is easy to wash, which can save water for multiple water washing, and do not need deoxygenation process, which can save water and other energy. Bugong tea saponin single auxiliary scouring and bleaching can effectively ensure that the fabric does not contain APEO and other harmful chemical elements, which is conducive to the safe export of textiles. The use of Pugong tea saponin can also reduce the COD concentration of wastewater by more than 30%, which has obvious environmental benefits. At present, Fujian Lianfengsheng Bleaching, Dyeing and Flocking Co., Ltd., Nantong Xinjinjiang Printing and Dyeing Co., Ltd., Zhejiang Xintianlong Printing and Dyeing Co., Ltd., Nantong Jinshida Printing and Dyeing Co., Ltd., Zhejiang Zhongfang Group, etc. are all in use.

The main feature of Bugong tea saponin used in chemical fiber woven fabrics is that it replaces many auxiliaries used in the traditional process of original chemical fiber woven fabrics. The pretreatment of chemical fiber woven fabrics is completed in one dosage form, which not only has a high desizing rate, brightens the fabric background, dyes brightly, but also can remove mold spots on the fabric, especially the anti staining phenomenon of polyester fabrics is reduced, and the dyeing color matching rate is high, The operator is simple and safe to operate. The main application customers are Fujian Longxinglong Printing and Dyeing Co., Ltd., Fujian Wanxinglong Printing and Dyeing Co., Ltd., Huzhou Chengxin Textile Co., Ltd., Nantong Changlin Textile Co., Ltd., and Changxing Hongfeng Textile Printing and Dyeing Co., Ltd., with good market feedback.

The biggest highlight of the pretreatment of knitted fabric with Bugong tea saponin is that it can reduce the weight loss rate of the fabric. Not only can the quality index of semi-finished products meet the requirements of the fabric before dyeing, but also the hand feel is soft and fluffy, which can save the use of softeners and anti puncture agents in the subsequent process. At the same time, since the use of Bugong tea saponin in one dosage form is sufficient, and no chemicals such as caustic soda, soda ash, hydrogen peroxide, penetrant, etc. are added, there will be no quality accidents due to omission or forgetting of additives, which can improve the success rate of color matching and reduce defects. Bugong tea saponin can effectively replace various auxiliaries used in the traditional refining and bleaching process. Generally, it is unnecessary to add caustic soda, hydrogen peroxide and other chemical additives when using fabrics. Special fabrics can obtain better whiteness and wool effect by using a very small amount of hydrogen peroxide for coordination, which can meet the requirements of fabric pretreatment. It is suitable for the one-time pretreatment of cotton, polyester, blended fabrics such as refining, seed removal, impurity removal and bleaching. The strength damage and weight loss rate of the fabric are less than those of the original traditional process, so it is simple and safe to use. It not only reduces wastewater discharge and COD concentration, but also reduces labor intensity of workers and improves product quality while saving water, electricity and steam. At present, Zhangjiagang Junma Textile Co., Ltd., Fujian Longsheng Knitting Co., Ltd., Zhejiang Shangyu Jinchen Printing and Dyeing Co., Ltd., Shanghai Jingsheng Printing and Dyeing Co., Ltd., Nantong Sanqi Textile Co., Ltd. are all in use.